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Formax 7200 Series Instruction Manual

Mid-volume modular inserting system
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Formax 7200 Series
Folder and Inserter
Instruction Manual

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Summary of Contents for Formax 7200 Series

  • Page 1 Formax 7200 Series Folder and Inserter Instruction Manual...
  • Page 2 7200 Series Mid-Volume Modular Inserting System OPERATOR MANUAL FIRST EDITION 12/2011...

  • Page 3: Table Of Contents

    Table Of Contents 1 Introduction ..................3 Pictograms ................3 1.2 Notes on the use of this handbook ..........4 2 Safety notes ..................4 2.1 General safety notes ..............5 2.2 End of life ................6 3 Description of machine ................ 8 3.1 Description of operation ............
  • Page 4 9 Operator Maintenance ............... 51 9.1 Cleaning the sensors ...............51 9.2 Clearing paper jams ..............57 9.3 Changing the feed tyres ............59 9.4 Adjust the CIS reader ..............60 10 Technical Specification ..............61 10.1 Inserter head ...............61 10.2 Flex tower ................66 10.3 Versatile feeder ..............68 10.4 Mechanical &...

  • Page 5: Introduction

    1 Introduction With this inserter you have an advanced, medium-volume folding and inserting machine. Its modular construction allows up to 8 feed units to be fitted, with a maximum of 11 feed trays. Its sophisticated software control optimises the order and flow of documents for collating at the insert head before insertion into the envelope.

  • Page 6: Notes On The Use Of This Handbook

    1.2 Notes on the use of this handbook This document contains all general information and explanatory text necessary in order to be able to carry out the operation of the machine. When some action is expected from the operator, this will always be explicitly stated, and where relevant, accompanied by an illustration or graphic.

  • Page 7: General Safety Notes

    2.1 General safety notes Caution! Please, read these notes with care. Save these instructions for later use. All notes and warnings found on the machine are to be followed. Important! The machine must be installed only by an Authorised Installing Service Engineer.

  • Page 8: End Of Life

    Allow In the following cases, the mains plug must be unplugged and the device left for the authorized Service Agents: machine to • When the mains cable or plug is worn or damaged. be checked • When water or other liquid has entered the device. by the •...
  • Page 9 In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronic equipment is marked with the following logo: Do not mix with normal domestic waste. Please use the subjoined return or collection system dedicated to electrical and electronic waste.

  • Page 10: Description Of Machine

    3 Description of machine • Feeder Folder - Mounts on the track, 3.1 Description of operation either in conjunction with a tower (see below) or as the last station. Fitted with The function of the machine is to fold forms one feed hopper, and folds forms up to to ‘C’, ‘Z’, ‘V’...

  • Page 11: Identification Of Parts

    3.2 Identification of parts The main parts of the machine are shown below. Envelope feeder Holds up to 800 envelopes (DL). Fiited with a sensing conveyor that operates on demand to move the envelope stack forward. Touch-screen monitor Runs the IMOS operating software and responds to button pushes. A key- board and mouse are also included.
  • Page 12 Feed Pods Fitted to the Flex Tower. Either a 1-Tray or a 2-Tray Flex Tower is available. Each one is fitted with either 2 x 500-sheet trays, or 1 x 1000-sheet tray; both variants can be mark reading as an option. Accumulator Fitted to the Flex Tower and allows groups of forms to be collated together before folding as a group.

  • Page 13: Control Panel

    4 Control Panel 4.1 The Job Screen This is the screen displayed when the machine starts up. section 5 section 6 List of existing jobs– see section 5 Graphic shows machine section 7 configuration See section 5 for running an existing job directly from this screen.

  • Page 14: The Run Screen

    4.2 The Run Screen 4.2.1 The Run Screen displayed This is the screen you will see after an existing job has been selected in the Job Menu. See section 6 Close IMOS* See section 4.1 Paper load indicators See section 3 Pause Autoend Zero the...

  • Page 15: To Adjust The Envelope Inserter Settings

    4.2.2 To adjust the Envelope Inserter settings Unit Fine Tuning All fine adjustments apply only to the current job and will not affect any other jobs. Select the inserter icon on the machine graphic in the Run screen to display the fine tuning screen.
  • Page 16 Hopper Fine Tuning From here you can adjust hopper settings. Select the envelope icon on the ma- chine graphic in the Run screen then Document Fine Tuning to display further information. You can change: a: Whether or not the envelope is sealed. Select ‘Off’ if, for example, later hand insertion of an insert or any other item will be required.

  • Page 17: To Adjust The Document Unit Settings

    4.2.3 To adjust the Document Unit settings Unit Fine Tuning The fine tuning options available will depend upon whether a Versatile Feeder or Flex Folder is fitted. Select the document or insert icon on the machine graphic in the Run screen to display the fine tuning screen.

  • Page 18: The Menu Screen

    4.3 The Menu Screen The Menu screen allows various functions to be selected. These functions are de- scribed in detail further in this document.

  • Page 19: Running An Existing Job

    5 Running an existing job This section describes running an existing pre-programmed job. To create a new job, see section 7. If the IMOS operating software is not already running, it must be started using the icon on the monitor screen. To access the PC to switch it on, open the cupboard below the inserter head.
  • Page 20 Load the paper and envelopes in the hoppers indicated. Press the Run but- ton to begin operating. See also section 4.2 for a full description of the controls.  Paper is normally loaded in the Tower face-up and feet-first if non- reading, face down and head-first if reading.

  • Page 21: Switching The User

    6 Switching the user 6.1 How to switch the user Each user has their own password and access rights, allocated by the Supervisor. To switch user, the password must be known. Press the Switch User button in the Job screen Select the user from the list.
  • Page 22 Enter the password using either the keyboard or the on-screen keypad. The user has now changed. Press the Login button. 6.2 User Access Rights There are 4 levels of access rights that can be allocated to each user. These are described below: Rights Operator...

  • Page 23: Creating A Job

    7 Creating a job Creating a job consists of a number of steps: • Defining the Mailset (Envelope, document & enclosures) • Defining the Fold Settings • Setting required Output Options • Saving the Job to a Jobname When defining the Document in the Mailset, OMR or Barcode definitions can be en- abled if required.

  • Page 24: Defining The Mailset

    7.1.1 Defining the mailset Selecting the envelope Press the Select button to choose an en- velope from the available library. Select the required envelope from the library and press the OK button. If there are no envelopes in the library, or if you wish to create a new one, see section 7.3.
  • Page 25 You now have a choice: carry on to select a document, or further define the envelope us- age, ie. sealing mode and deskew. The following assumes you want to further define the envelope usage. When you have finished you will return to the screen shown here.
  • Page 26 From here, you can turn adjust the degree of deskew, or turn it off if you require. This might be done to speed the ma- chine up if, for example, an envelope is unlikely to skew, eg. a C5 or other longer envelope.
  • Page 27 Selecting the document Press the Select button to choose a docu- ment from the available library. Select the required document from the library and press the OK button. If there are no documents in the library, or if you wish to create a new one, see section 7.4.
  • Page 28 You now have a choice: carry on to select enclosures, or further de- fine the document usage, eg. form count, cascading, hand-feed etc. The following assumes you want to further define the document usage. When you have finished you will return to the screen shown here.
  • Page 29 If you wish to choose an orientation oth- er than the auto-selected default, press Auto to en- able the selector button. If required adjust the degree of deskew, or turn it off if you require, for ex- ample if a document type is found to feed reliably without skewing.
  • Page 30 Selecting the enclosure If you are using enclosures (inserts, BREs, booklets etc.), press the Select button. Select the required enclosure from the library and press the OK button. If there are no enclosures in the library, or if you wish to create a new one, see section 7.5.
  • Page 31 You now have a choice: carry on to select further enclosures if re- quired, remove the enclo- sure you have selected, or further define the en- closure usage, eg. form count, cascading, hand- fold etc. The following assumes you want to further define the enclosure usage.
  • Page 32 If further enclo- sures are required, press the Add button and repeat steps 13 to 18. Repeat as required up to the limit of available sta- tions. You now have a choice: to proceed and move on to Fold Settings, or to assign the documents/enclosures to specific hoppers.

  • Page 33: Defining The Fold

    The mailset is now defined, and the screen will show that this is ticked. You will now define the fold settings. 7.1.2 Defining the fold The machine will automatically select the optimum fold type. If you wish to change this, de- select ‘Auto’...
  • Page 34 If you wish to make adjustments to the collation mode or Max no. of sheets folded together, press the Edit advanced settings button. Choose whether to collate leading edges of documents as they feed through the folder, then folded together without entering the accumula- tor, or to feed separately into the accumulator be-...

  • Page 35: Defining The Output Settings

    7.1.3 Defining the output settings Select whether batch mode is to be used, and the quantity. The machine will then process this number of cycles, then stop. This will be repeated until the machine is stopped. To define the batch jog steps, franker and MPPC modes, press the Edit ad- vanced settings button.
  • Page 36 Mode Options • Not Used: The franking conveyor will be driven like a standard con- veyor, pulsed on each envelope. • Dumb: The franking conveyor will be run continuously while the in- serter is running. • Pass-through: Level 2/3 function – envelopes will not be franked. •...

  • Page 37: Saving The Job

    The output settings are now defined, and the screen will show that this is ticked. You will now save the job. 7.1.4 Saving the job Press the keyboard icon to display the virtual keyboard. Enter a name for the job using either the virtual or physical key- board.

  • Page 38: Creating An Envelope

    7.2 Creating an envelope In order for an envelope to appear in the envelope library, it must first be created. Begin creating a job (see section 7.1) At the point where you need to select an en- velope, press the Create button.
  • Page 39 Adjust the weight as required. Note that the weight is the actual weight of the envelope, not the paper weight. Press the Save button when done. The envelope will now be available in the envelope library under the name you have given it. The envelope is now fully defined and is available for use.

  • Page 40: Creating A Document

    7.3 Creating a document In order for a document to appear in the document library, it must first be created. Begin creating a job (see section 7.1). At the point where you need to select a docu- ment, press the Create button.
  • Page 41 Select the address position. This defaults to ‘Top’; specify middle, bot- tom or none if required. Specify whether the docu- ment is to be folded (eg. a booklet iwould not be) and its thickness and weight. Note this is the actual weight of the document, not the paper weight.

  • Page 42: Creating An Enclosure

    7.4 Creating an enclosure In order for an enclosure to appear in the enclosure library, it must first be created. Begin creating a job (see section 7.1). At the point where you need to select an en- closure, press the Create button.

  • Page 43: Loading The Paper Hoppers

    8 Loading the paper hoppers 8.1 Loading the envelope hopper Using the black knob, adjust the side guide to give 1-1.5mm clearance each side of the envelope. Adjust the angle of the backrest (see below) and load the envelopes into the hopper, flaps forward so that the lower edges follow the contour of the...

  • Page 44: Loading The Versatile Feeder Hopper

    8.2 Loading the versatile feeder hopper 1. Slacken the black knob next to the side guides (arrowed) and move the guides to give 1-1.5mm clearance each side of the enclosure. Tighten the knob. 2. Slacken the black knob under the backrest (arrowed) and move it forwards to support the enclosures as shown.
  • Page 45 1. Look into the aperture shown and you will see the setting gauge on the side of the separator unit. There is an 80gsm mark as a starting point for single sheets, and mm settings underneath the 0 line for booklets etc. See also section 8.5 ‘Daily Post’.
  • Page 46 1000 Sheets of 80gsm (20lbs bond) or 400 BRE (DL) 130 x 2.5mm A5 Booklets 40 x 6mm A4 Booklets 500 x 0.5mm A5 Booklets...

  • Page 47: Loading The Flex Folder Hoppers

    8.3 Loading the flex folder hoppers The flex folder may be fitted with 500-sheet or 1000-sheet hoppers, or only a single 500-sheet hopper. The example shown has 2 x 500-sheet and 1 x 1000-sheet hoppers. 1. On 500-sheet hoppers, slacken the black knob next to the side guides (arrowed) and move the guides to give 1-1.5mm clearance each side.
  • Page 48 Fold Plate 2 If fold-plate 2 is being used in the folding operation, it must be adjusted as shown below (see chart on the following page for guide on fold plate usage). 1. Open the side cover on the flex folder. Slacken the fold plate knob indicated and adjust it according to the length...
  • Page 49 Paper Orientations Paper orientations for various applications are shown below. European Sizes: American Sizes:...

  • Page 50: Paper Control Lever

    8.4 Paper Control Lever The paper control lever is located in the collate area, and raises or lowers overguide strips in the paper path. For normal running, the overguide strips should be lowered to assist paper movement. However, in some cases (such as a single lightweight sheet, or a thick pack with a lightweight prime document on top), it may assist paper movement to raise the overguide strips.

  • Page 51: Daily Mail (Handfeed)

    8.5 Daily Mail (Handfeed) Daily post allows a group of forms to be hand-fed, folded and inserted on a Versatile Feeder. A group of forms up to a total of 6mm thick may be fed, but be aware of the folding capacity of 8 forms of 80gsm (20lbs bond). The forms may be stapled or not, as required (see below for stapling restrictions).

  • Page 52: Setting The Separator Gap (See Also Section 8.2 'Adjusting The Separator')

    8.5.3 Setting the Separator Gap (see also section 8.2 ‘Adjusting the Sepa- rator’). Now set the separator gap to suit the daily mail. As a general guide, the gap should be set to approx. 1mm greater than the pack or booklet thickness. If the document is an 80gsm sheet, set the gap to 1mm.

  • Page 53: Operator Maintenance

    9 Operator Maintenance 9.1 Cleaning the sensors The optical sensors consist of two halves: emitter and receiver. These can become obstructed due to paper dust and should periodicaly be cleaned using a non- flammable airduster. Both halves must be cleaned. This section shows where the sensors are located.
  • Page 54 Picture is viewed looking inside the collation area away from the envelope hopper. Clean all sensors arrowed. Lower the collate clamshell and open the upper conveyor (furthest from the envelope hopper) so that it locks in place. Picture is viewed looking inside the collation area away from the envelope hopper.
  • Page 55 Picture is viewed looking down on the envelope hopper, at the front. Clean the one-piece reflective sensor.
  • Page 56 Versatile Feeder Open the feeder top covers at the front, if the feeder is the first station. If a subsequent station, open the side cover and approach from the side. Picture is viewed looking towards the front. Clean the sensor arrowed. The upper half is located on a bracket above the lower half.
  • Page 57 Open the side cover and push the lowermost lever forward to lower the conveyor. Clean the sensor located in the centre of the track as shown, with the upper half directly above it.
  • Page 58 Flex Folder Open the folder top cover and clean the sensors indicated. For the two sensors shown side-by-side, direct the nozzle of the airduster into the gap at the front of the them and spray liberally. Open the side cover and raise the two transport assemblies so that they TRANSPORT...

  • Page 59: Clearing Paper Jams

    9.2 Clearing paper jams If paper jams occur, the area affected will normally be shown in the error message on the screen. Use one of the clearance methods described below to clear the jammed paper. Inserter head Open the side cover on the operator side of the machine. Versatile Feeder Open the side cover on the versatile feeder.
  • Page 60 Tower Unit Using the release handle, swing open the vertical platten indicated and latch it in place. Raise the roller assembly below them to access the jammed paper. Note: the roller assembly does not latch in place. If the paper is not fully visible, turn the blue knobs to wind it into view.

  • Page 61: Changing The Feed Tyres

    9.3 Changing the feed tires Certain documents (eg. glossy materials) may not not feed properly with the standard feed rollers. Sets of optional feed tires are available to assist feeding. These can be fitted as follows. Remove the 3 knobs indicated and open the side guides to their widest extent.

  • Page 62: Adjust The Cis Reader

    9.4 Adjusting the CIS reader If a CIS reader is fitted to a Flex Folder, it must be adjusted to align with the label, as described below On a 500-sheet hopper pod, remove both feed trays to access the CIS reader as shown.

  • Page 63: Technical Specification

    10 Technical Specification 10.1 Inserter head Pack thickness Maximum pack thickness is defined as the internal dimension of a rigid opening that a filled envelope will fall through under its own weight. #10 & DL Envelopes: up to 6mm (¼”) C5/C4 Envelopes and above: up to 6mm (¼”) Pack clearance The minimum clearances required between the inserts and envelopes are dependent on insert pack thickness. Clearance is the total clearance and is defined as the difference between the largest overall dimensions of the pack and the internal dimensions of the envelope (see below). The required clearances are summarised as follows: Pack <3mm: Depth 6mm (¼”) Width 16mm (5/8”) Pack >3mm <6mm: Depth 12mm (½”) Width 19mm (¾”) Width Clearance Insert Envelope Cycling speed Up to 4800 envelopes per hour (based on 1 x A4 folded sheet into a C5/C65 or DL or #10 (114mm x 229mm) envelope). Up to 3900 envelopes per hour (based on 1 x A4 folded sheet with 1 x enclosure into a C5/C6 or DL or #10 (114mm x 229mm) envelope). Speeds for other conditions available on request.
  • Page 64 Monthly volume Up to 200,000 filled envelopes per month. C5 or below - up to 800 of 90gsm (20lbs bond) Envelope C4 (flat type) - up to 100gsm (28lbs bond) Hopper capacity Envelope weight Minimum: C5 or below - 70gsm (18lbs bond) Minimum: Above C5 - 90gsm (24lbs bond) Maximum: 110gsm (28lbs bond) •...
  • Page 65 Envelope details Side Seam style envelope Min. 10mm Body Depth Minimum open ") Flap Length Max. 254mm(10") throat area Max. 65mm (2½") Min. Min. 98.5mm(3 7/8") Flap Shoulder Angle Throat angle Min. 32mm (1 ") 10mm 50°Min. 90°Max. 5°Min. 20°Max. ") Min.70mm (2 ")
  • Page 66 Position of internal side seams to give a minimum of 5mm ( ") clearance or overlap to the edge of any insert Flap crease to be scored sufficiently to prevent distortion of envelope between window and flap crease when closing and sealing. Top edge of window to be flat and free from puckering Glue area...
  • Page 67 Maximum distortion allowable on a twisted envelope to be 10mm ") when envelope measured sitting flat on a table Built-in wetter tank, automatically pump-fed by 10-litre Envelope wetter container located in stand. Optional low-level float sealing fluid switch available.

  • Page 68: Flex Tower

    10.2 Flex tower Paper Size Minimim width: 148mm (5¾”) Maximum width: 305mm (12”) Minimum length: 93mm (3 ⅝”) Maximum length: 406mm (16”) Paper weight Minimum 70gsm (18lbs bond) Maximum 120gsm (32lbs bond) Folding capacity C, Z or V-fold: 8 sheets 80gsm (18lbs bond)* Double-forward fold: 4 sheets 80gsm (18lbs bond)* * Multiple folded sets dependent upon pack thickness.
  • Page 69 Daily mail Up to 8 sheets of 80gsm (20lbs bond) for C, Z or V fold, up to 4 sheets of 80gsm (20lbs bond) for double forward fold, up tp 25 sheets of 80gsm (20lbs bond) unfolded. May be stapled or not. Max. thickness of staple 3mm. Allowable staple positions are shown below.

  • Page 70: Versatile Feeder

    10.3 Versatile feeder Enclosure Size Minimim width: 148mm (5¾”) Maximum width: 305mm (12”) Minimum length: 93mm (3 ⅝”) Maximum length: 216mm (8½”) Enclosure weight Minimum 80gsm (20lbs bond) Maximum 6mm (¼”) thickness Hopper capacity 1000 sheets of A4 80gsm (18lbs bond) 500 sheets of A4 Z-folded 80gsm (18lbs bond) 250 x 2.4mm booklets 400 x C5 envelopes...

  • Page 71: Mechanical & Electrical

    10.4 Mechanical & Electrical Noise level: xxdbA (3 x Versatile feeders, 1 x Flex tower, measured at 1.6m height, 1m from nearest cover). Heat Output (BTU/Hour): Rated current x rated volts x 3.412 (eg. 2464 BTU/Hour for typical configuration of 3 x versa feeders + flex tower folder). Heat Output (Watts): Rated current x rated volts (eg.

  • Page 72: Glossary Of Terms

    11 Glossary of terms Term Description Address carrier The address carrier is the document that carries the address of the person for who the mail set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address.
  • Page 73 Term Description Document set The document set is the physical collection of address carrier and enclosure(s) that is under production in the inserting system. The document set is completed during production and is to be inserted into the envelope. The number of enclosures can range from 0 to the limit imposed by the number of available feeders, whilst observing the overall pack thickness.
  • Page 74 Term Description Feeder linking The ability to load two feeders with the same document type (Cascading) where the inserting system automatically switches to a second feeder when the first feeder is empty and vice versa. In the mean time the first feeder can be refilled, so the inserting system can keep running without having to stop for refilling the feeders.
  • Page 75 Term Description Optical Mark Optical Mark Recognition is intended for reading and interpreting Recognition printed codes. These codes are one or more black marks which (OMR) are read from a document. These marks give information to the inserting system about how to build-up and handle a set. Output Fitted at the output for filled envelopes to be ejected onto.
  • Page 76 Term Description Z-fold (also A Z-fold means that a document is folded twice in such a known as way that each folded flap is on a different size of the folded zigzag fold) document, resulting in a Z-shape. This fold is illustrated below. The position of both folds is adjustable.
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